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Operating Instructions
Flexi Classic Muting
This document is protected by the law of copyright, whereby all rights established therein remain with the
company SICK AG. Reproduction of this document or parts of this document is only permissible within the limits of
the legal determination of Copyright Law. Alteration or abridgement of the document is not permitted without the
explicit written approval of the company SICK AG.
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Operating Instructions
Inhalt
Inhalt
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On safety.............................................................................................................................8
2.1
Qualified safety personnel....................................................................................8
2.2
Field of application................................................................................................8
2.3
Correct use ............................................................................................................9
2.4
General safety notes and protective measures ..................................................9
2.5
Environmental protection ...................................................................................10
2.5.1
Disposal .............................................................................................10
2.5.2
Separation of materials ....................................................................10
Muting...............................................................................................................................11
3.1
Muting principle ..................................................................................................12
3.1.1
Muting cycle.......................................................................................12
3.1.2
Muting sensors..................................................................................12
3.1.3
Muting lamp ......................................................................................13
3.2
Arrangement of muting sensors.........................................................................14
3.2.1
Muting with two sensors (a pair of sensors), crossed
arrangement......................................................................................15
3.2.2
Muting with two sensors (a pair of sensors), crossed
arrangement, and a supplementary signal......................................17
3.2.3
Muting with four sensors (two pairs of sensors), sequential
arrangement......................................................................................18
3.2.4
Muting with four sensors (two pairs of sensors), parallel
arrangement......................................................................................20
Product description.........................................................................................................22
4.1
Special features ..................................................................................................22
4.2
System structure .................................................................................................23
4.2.1
Muting main module UE410-MM.....................................................23
4.2.2
Connections to muting expansion module UE410-XM ...................25
4.2.3
Muting expansion module UE410-MDI............................................26
4.3
Flexi Classic Muting in the Flexi family ..............................................................27
4.4
Module description .............................................................................................28
4.4.1
Module description UE410-MM and UE410-XM .............................29
4.4.2
Module description UE410-MDI .......................................................31
Inhalt
Operating Instructions
Flexi Classic Muting
Configurable functions................................................................................................... 32
5.1
Number of muting sensors ................................................................................ 32
5.1.1
Supplementary signal C1 ................................................................. 32
5.2
Time monitoring.................................................................................................. 33
5.2.1
Concurrence monitoring................................................................... 33
5.2.2
Monitoring the total muting duration .............................................. 34
5.2.3
Sensor gap monitoring ..................................................................... 34
5.2.4
Conveyor stopped (CS) ..................................................................... 34
5.2.5
Muting end by ESPE ......................................................................... 35
5.3
Direction recognition .......................................................................................... 36
5.4
Sequence monitoring ......................................................................................... 36
5.5
Override function ................................................................................................ 37
5.6
Restart interlock ................................................................................................. 39
5.6.1
Reset ................................................................................................. 40
5.7
External device monitoring (EDM) ..................................................................... 40
10 Commissioning................................................................................................................ 51
10.1 Application acceptance ...................................................................................... 51
10.2 Testing instructions ............................................................................................ 52
10.2.1
Tests before first commissioning..................................................... 52
10.2.2
Periodic testing ................................................................................. 52
10.2.3
Regular inspection of the protective installation by a
competent person ............................................................................ 52
10.3 Meanings of optical signals ............................................................................... 53
11 Configuration................................................................................................................... 54
12 Diagnosis ......................................................................................................................... 55
12.1 Behavior in the event of an error....................................................................... 55
12.2 Safe state in case of an error ............................................................................ 55
12.3 SICK support ....................................................................................................... 55
12.4 Error-LED displays (ERR) .................................................................................... 56
12.5 Anti-manipulation measures.............................................................................. 57
13 Technical data ................................................................................................................. 58
13.1 Data sheet........................................................................................................... 58
13.1.1
Module UE410-MM/UE410-XM....................................................... 58
13.1.2
Special data UE410-MDI.................................................................. 61
13.2 Dimensions ......................................................................................................... 62
13.2.1
Main module UE410-MM ................................................................. 62
13.2.2
Modules UE410-XM and UE410-MDI .............................................. 62
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Operating Instructions
Inhalt
14 Ordering information.......................................................................................................63
14.1 Available modules ...............................................................................................63
14.2 Accessories and spare parts ..............................................................................64
14.2.1
Non-contact safety switches.............................................................64
14.2.2
Safety light curtains, multiple light beam safety devices ...............64
14.2.3
Muting lamp with cable.....................................................................64
14.2.4
Anti-manipulation cap.......................................................................64
15 Annex ................................................................................................................................65
15.1 EC declaration of conformity ..............................................................................65
15.2 Checklist for the manufacturer ..........................................................................67
15.3 List of tables ........................................................................................................68
15.4 List of figures.......................................................................................................69
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Chapter 1
Operating Instructions
Flexi Classic Muting
1.1
These operating instructions are designed to address the technical personnel of the
machine manufacturer or the machine operator with regard to the safe mounting,
installation, configuration, electrical installation, commissioning, operation and
maintenance of the Flexi Classic Muting modular safety controller.
These operating instructions do not provide instructions for operating machines on which
the Flexi Classic Muting has been, or could be integrated. Information on this is to be
found in the appropriate operating instructions for the machine.
1.2
Target group
1.3
Depth of information
These operating instructions contain information about the Flexi Classic Muting modular
safety controller on the following subjects:
installation and mounting
electrical installation
part numbers
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Operating Instructions
Chapter 1
1.4
Scope
These operating instructions are valid for all Flexi Classic Muting modular safety
controllers. You must also take into account the relevant Brief Operating Instructions (see
entries on the device type labels on the modules).
1.5
EDM
ESPE
OSSD
Output signal switching device = Signal output which controls a safety circuit
PLC
SIL
1.6
Recommendation
Red,
Red,
Abbreviations employed
Symbols used
Note
Green
Take action
Instructions for taking action are shown by an arrow. Read the take-action instructions
carefully and follow them precisely.
Warning!
WARNING
A warning notice indicates an actual or potential hazard. Warnings are intended to help
protect you from accidents.
Read warnings carefully and follow them precisely!
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On safety
Chapter 2
Operating Instructions
Flexi Classic Muting
On safety
This chapter deals with your own safety and the safety of persons operating the equipment.
Please read this chapter carefully before starting to work with the Flexi Classic Muting
modular safety controller or with machinery protected by a Flexi Classic Muting.
2.1
The Flexi Classic Muting modular safety controller must be mounted, commissioned and
serviced only by qualified safety personnel.
Qualified safety personnel are defined as persons who
have undergone the appropriate technical training
and
who have been instructed by the responsible machine operator in the operation of the
machine and the current valid safety guidelines
and
have access to the operating instructions of the Flexi Classic Muting and those of the
particular modules and have read and familiarised themselves with them
and
have access to the operating instructions for the protective devices (e.g. C4000) connected to the safety controller and have read and familiarised themselves with them.
2.2
Field of application
The Flexi Classic Muting family is a range of modules within the Flexi Classic family.
These muting modules can be used to solve both simple and more complex muting
applications. Configuration is carried out by setting rotary switches on the modules.
The category in accordance with EN ISO 13 849J1 or the SIL in accordance with IEC 61 508
and the SILCL in accordance with EN 62 061 depend on the external circuit, the realisation
of the wiring, the choice of the sensors and their location at the machine.
Note
The safety level of the device corresponds to up to SIL3 in accordance with IEC 61 508, up
to SILCL3 in accordance with EN 62 061, PL e in accordance with EN ISO 13 849J1 and
category 4 in accordance with EN ISO 13 849J1. The emergency stop function in the device
corresponds to stop category 0 in accordance with EN 60 204J1.
In order to reach the SIL3 safety level (see chapter 13 Technical data on page 58) in
accordance with IEC 61 508, the following test must be made at least every 365 days:
The Flexi Classic Muting system must be powered down.
The Flexi Classic Muting system must be powered up.
All safety functions of the connected safety sensors must be verified.
The type of safety sensors as well as the method of wiring must be chosen according to
the category which is to be achieved.
Opto-electronic and tactile safety sensors (e.g. light curtains, laser scanners), muting
sensors (photoelectric switches, photoelectric proximity switches, inductive proximity
switches, ) as well as additional signals from other sensors or from the higher level
controller are connected to the Flexi Classic Muting modular safety controller. Via the
switching outputs on the safety controller the related actuators on the machines or in the
systems can be muted or safely shut down as per the muting function configured.
The modular safety controller Flexi Classic Muting has been tested in accordance with UL 508.
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Operating Instructions
On safety
Chapter 2
2.3
Correct use
The Flexi Classic Muting modular safety controller is only to be used as defined in section 2.2 Field of application. It must be used only by qualified personnel and only on a
machine on which it has been installed and initialised by competent personnel in accordance with these operating instructions.
If the device is used for any other purposes or modified in any way including during
mounting and installation any warranty claim against SICK AG shall become void.
2.4
Please observe the following items in order to ensure correct use of the Flexi Classic
Muting safety controller.
When mounting, installing and using the Flexi Classic Muting, observe the standards
and directives applicable in your country.
The national/international rules and regulations apply to the installation, use and
periodic technical inspection of the Flexi Classic Muting safety controller, in particular
Machinery Directive 2006/42/EC,
EMC Directive 2004/108/EC,
Provision and Use of Work Equipment Directive 2009/104/EC,
Low-Voltage Directive 2006/95/EC,
the work safety regulations/safety rules.
Manufacturers and owners of the machine on which a Flexi Classic Muting is used are
responsible for obtaining and observing all applicable safety regulations and rules.
The notes, in particular the test notes of these operating instructions (e.g. on use,
mounting, installation or integration into the existing machine controller) must be
observed (see section 10.2 Testing instructions on page 52).
The tests must be carried out by qualified safety personnel or specially qualified and
authorised personnel and must be recorded and documented to ensure that the tests
can be reconstructed and retraced at any time by third parties.
These operating instructions must be made available to the operator of the machine
where the Flexi Classic Muting is used. The machine operator is to be instructed in the
use of the device by qualified safety personnel and must be instructed to read the
operating instructions.
The external voltage supply of the device must be capable of buffering brief mains
voltage failures of 20 ms as specified in EN 60 204. Suitable power supplies are
available as accessories from SICK.
The modules of the Flexi Classic Muting family conform to Class A, Group 1, in accordance with EN 55 011. Group 1 encompasses all ISM devices in which intentionally generated and/or used conductor-bound RF energy that is required for the inner function of
the device itself occurs.
The Flexi Classic Muting system complies, as per the radiated emissions generic
standard, with the requirements of class A (industrial applications).
WARNING
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The Flexi Classic Muting system is therefore only suitable for use in an industrial environment.
On safety
Chapter 2
Operating Instructions
Flexi Classic Muting
2.5
Environmental protection
The Flexi Classic Muting modular safety controller is designed so that it has the least
possible impact on the environment. It consumes only a minimum of energy and
resources.
Always act in an environmentally responsible manner at your workplace.
2.5.1
Disposal
We would be pleased to assist you to dispose of this device. Just contact us.
2.5.2
Separation of materials
Components
Disposal
Product
Body, PCBs, wiring, plugs and
electrical connectors
Electronics recycling
Packaging
Cardboard, paper
10
Paper/cardboard recycling
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Operating Instructions
Muting
Chapter 3
Muting
Always observe the following safety instructions!
WARNING
Muting must only be activated for the period of time during which the transported
material (e.g. on a pallet) blocks access to the hazardous area.
Muting must take place automatically, but must not be dependent on a single electrical
signal.
Muting must be triggered by at least two independently wired signals (e.g. from muting
sensors) and must not depend entirely on software signals (e.g. from a PLC).
The muting condition must be cancelled as soon as the transported material no longer
blocks access to the hazardous motion, so that the protective device becomes effective
again.
The material to be transported must be detected over its entire length, i.e. there must
be no interruption in the output signals.
Mount control switches for reset and override outside the hazardous area so that they
cannot be operated by a person inside the hazardous area. In addition, when operating
control switches, the operator must have full visual command of the hazardous area.
Always position muting sensors so that the minimum safety distance to the safety
device is complied with.
Muting sensors must be positioned so that a person cannot unintentionally activate the
muting function (see illustrations below)!
A: It may not be possible to activate sensors lying opposite each other simultaneously.
B: It may not be possible to activate sensors mounted next to each other simultaneously.
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11
Muting
Chapter 3
Operating Instructions
Flexi Classic Muting
3.1
Muting principle
Muting is the temporary bypassing of the protective action of a safety device. In this way,
material can be permitted to pass to or from a machine or plant without the need to
interrupt a work process.
With the aid of additional sensor signals, muting distinguishes between objects and persons. A controller (e.g. the Flexi Classic Muting switch unit) logically evaluates the signals
from external sensors and, when the muting conditions are valid, bypasses the protective
device, so that the material being transported can pass the protective device. Immediately
anything other than the material enters the hazardous area, the work process is
interrupted.
Fig. 2: Detection of material
during muting
Means of transport
Material
ESPE
Hazardous area
M1
M2
In the above figure, the material moves on a conveyor from left to right. As soon as the
muting sensors M1 and M2 are activated , the protective action of the protective device
ESPE is bypassed and material can enter the hazardous area. As soon as the muting
sensors are free again , the protective action of the protective device is reactivated.
3.1.1
Muting cycle
The muting cycle is the fixed sequence of all procedures encompassed by muting. The
cycle begins when the first muting sensor is activated. It ends when the last muting sensor
returns to its initial state (e.g. free optical path for optical sensors). Muting can only then
become active again.
Within a muting cycle, the material can be transported several times if the muting condition is continuously maintained, i.e. at least one pair of sensors remains continuously
activated.
3.1.2
Muting sensors
Muting sensors detect material and supply the necessary signals that a controller (e.g. a
Flexi Classic Muting safety controller) needs. When the muting conditions are fulfilled, the
controller will bypass the protective installation on the basis of the sensor signals.
If additional functions, e.g. C1 or conveyor stopped (CS) have been selected (only with
UE410-MDI), these control signals also are evaluated (usually by a higher-level control
system).
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Muting
Operating Instructions
Chapter 3
Type
Function
W9-3
W12-3
W18-3
W27-3
W24-3
Note
For the selection and setting of SICK optical muting-sensors for muting applications, the
following apply:
Sensor outputs must be PNP switching.
Other component ranges can also be chosen.
Observe the output levels given in Table 3.
Status
HIGH
LOW
3.1.3
Muting lamp
To signal muting, it is recommended that a muting lamp is installed. The muting lamp
indicates temporary muting.
Install the muting lamp so that it is always clearly visible!
WARNING
The muting lamp must be visible from all sides around the hazard zone and for the plant
operator.
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13
Muting
Chapter 3
Operating Instructions
Flexi Classic Muting
3.2
WARNING
Always position muting sensors such that material can pass unhindered, but people are
reliably detected.
Fig. 3: Detection of material
during muting
Transport means
Material
Muting sensor
Transport level
Note
The minimum distance ensures that there is sufficient time for processing data before
muting is activated.
ESPE
Hazard zone
v t +t
d
res
Where
L
= Minimum distance[m]
td
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Operating Instructions
Muting
Chapter 3
Use optical sensors with background suppression. This type of sensor recognises material
presence only within a fixed distance. Objects that are further away are ignored.
Fig. 5: Function of sensor
with background suppression
Detection zone
Background
Sensor
Material is
recognised
3.2.1
Material is not
detected
Hazard zone
L2
L1
M1
M2
L3
ESPE
In the example, the material moves from left to right, or, alternatively, from right to left. As
soon as muting sensors M1 and M2 are activated, the protective action of the protective
device (ESPE) is bypassed.
The following conditions must be met
Tab. 4: Conditions for muting
with a pair of crossed
sensors
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Condition
Description
M1 & M2
15
Muting
Chapter 3
Operating Instructions
Flexi Classic Muting
L1
v (t d + t res )
v t > L2 + L3
Where
L1 = Minimum distance between the ESPE light beams and the point of detection by
muting sensors [m]
L2 = Distance between the two detection lines of the sensors (sensors activated/sensors
free) [m]
L3 = Length of material in direction of travel [m]
v
td
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Operating Instructions
Muting
Chapter 3
3.2.2
L2
Hazard zone
L1
C1
M1
M2
L3
L4
ESPE
The protective action of the protective device is bypassed when the muting sensors are
activated in a defined sequence. The muting Sensor (Signal C1) must always be activated
before both muting sensors of a pair (e.g. M1 and M2) (see section 5.1.1 Supplementary
signal C1 on page 32).
Muting sensor input requirements
Tab. 5: Conditions for muting
with a pair of sensors and a
supplementary signal
Condition
Description
C1 & M1 & M2
M1 & M2
L1
v (t d + tres )
v t > L2 + L3
L4 < L3
Where
L1 = Minimum distance between the ESPE light beams and detection by the
muting sensors [m]
L2 = Distance between the two detection lines of the sensors
(sensors activated/sensors free) [m]
L3 = Length of material in direction of travel [m]
L4 = Maximum distance between C1 and the detection line of M1, M2 [m]
v
td
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17
Muting
Chapter 3
Operating Instructions
Flexi Classic Muting
Note
ESPE
Hazard zone
L3
M1
M2
M3
M4
L1
L2
In the example, material moves from left to right. As soon as muting sensors M1 & M2 are
activated, the protective action of the protective device (ESPE) is bypassed. The protective
action remains bypassed until one sensor of the pair of muting sensors M3 & M4 is free
again.
Muting sensor input requirements
Tab. 6: Conditions for muting
with four sequential sensors
18
Condition
Description
M1 & M2
(or M3 & M4)
M3 & M4
(or M1 & M2)
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Muting
Operating Instructions
Chapter 3
L1
v 2 (t d + tres )
v t > L1 + L 3
L2 < L3
Where
L1 = Distance between the inner sensors (positioned symmetrically about the
ESPE light beams) [m]
L2 = Distance between the outer sensors (positioned symmetrically about the
ESPE light beams) [m]
L3 = Length of material in direction of travel [m]
v
td
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19
Muting
Chapter 3
Operating Instructions
Flexi Classic Muting
3.2.4
ESPE
L1
M1
M3
M2
M4
L3
In the example, material moves from left to right. As soon as the first pair of muting
sensors M1 & M2 is activated, the protective action of the protective device (ESPE) is
bypassed. The protective action remains bypassed until the pair of muting sensors
M3 & M4 is free again.
Muting sensor input requirements
Tab. 7: Conditions for muting
with four sensors arranged in
parallel
20
Condition
Description
M1 & M2
(or M3 & M4)
M3 & M4
(or M1 & M2)
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Muting
Operating Instructions
Chapter 3
L1
v 2 (t d + tres )
v t > L1 + L 3
L1 < L 3
Where
L1 = Distance between the inner sensors (positioned symmetrically about the
ESPE light beams) [m]
L3 = Length of material in direction of travel [m]
v
td
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21
Product description
Chapter 4
Operating Instructions
Flexi Classic Muting
Product description
This chapter informs you about special features of the Flexi Classic Muting modular safety
controller. It describes the structure and the function of the device.
Be sure to read this chapter, before you install the equipment, configure or commission
the device.
4.1
Special features
The Flexi Classic Muting family is part of the larger Flexi Classic family of safety controllers
that allow you to realise solutions for muting applications. These can be used either as an
autonomous safety system or connected together as an integrated muting system within a
Flexi system.
The compact housing of these modules is 22.5 mm wide.
Modules are plugged together, whereby communication between individual units occurs
on an internal bus (FlexBus).
The necessary muting functions and parameter settings are implemented using rotary
switches on the modules.
The Flexi Classic Muting family consists of 3 modules:
Main Muting UE410-MM (main module)
Expansion Muting UE410-XM (expansion module)
Muting Digital Input UE410-MDI (MDI module)
Note
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Operating Instructions
Product description
Chapter 4
4.2
System structure
The structure of a Flexi Classic Muting system depends on your muting application
requirements and on the other safety-related tasks you have to implement with the Flexi
Classic. The muting modules UE410-MM and UE410-XM will operate in conjunction with
other Flexi Classic components.
1. For a pure, isolated, basic muting application, such a system consists of a single main
module and, if necessary, modules from the Flexi Classic family, together with an
output module. An optional gateway can be connected for diagnosis.
2. If further muting functions have to be implemented in addition to the basic muting
function, then a muting Digital Input Module UE410-MDI is required in addition to the
system described under 1., above.
3. The system can be extended to two muting stations by adding a UE410-XM.
4. For diagnostics, gateways are available in the Flexi Classic family.
Fig. 11: Structure of the Flexi
Classic Muting modular
safety controller system
Muting Main
Muting Expansion
Output module
Gateway
UE410-MM
UE410-XM
UE410-MDI
UE410-2RO/
e.g.
UE410-4RO
UE410- PRO/
FIELDBUS
2/4 outputs
UE410- DEV/
UE410- CAN
(see operating instructions for
UE410 gateway)
4.2.1
The muting main module UE410-MM is the main module, in which the system configuration of the complete Flexi Classic Muting system is stored.
The muting main module UE410-MM can be used to implement basic muting functions
such as 2 or 4 sensor muting, with or without override. For this purpose it has 2 inputs
for connecting the main sensor that is to be muted, 4 inputs for the muting sensors, and
2 control inputs. Outputs from this module include 2 semiconductor-based, safety-rated
outputs, 2 signal outputs and 2 test outputs.
Mode of operation and parameters are configured using two rotary switches on the upper
surface of the module. The Function A rotary switch is used to define the mode of operation, with/without override, muting end condition and direction monitoring. The Function B
rotary switch is used to define muting duration and with/without concurrence monitoring
of sensors.
Functions such as EDM, restart etc. are implemented by control wiring to terminal S1.
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23
Product description
Chapter 4
Operating Instructions
Flexi Classic Muting
Inputs
Tab. 8: Inputs of the muting
main module
EN
S1
M1, M2
M3, M4
I1 and I2
Outputs
Tab. 9: Outputs of the muting
main module
Notes
Q1/Q2
Q3
X1/X2
Control outputs
Q4
Safe semiconductor outputs: The safe semiconductor outputs Q1 and Q2 on the UE410MM/XM module are used to control actuators. The outputs are suitable for loads up to
2 A, and are resistant to short-circuits. The switchability of the outputs is continuously
monitored. This is achieved by periodically switching off the outputs and checking the
resulting signal for the expected LOW state. When a fault is detected, the outputs are
switched off by removal of the control signal and switching the output current supply to
LOW.
When electromechanical relay contacts are required, they are available on output
modules UE410-2RO/UE410-4RO.
For further information on output modules UE410-2RO/UE410-4RO, see the Flexi
Classic operating instructions (8011737) or go to www.sens-control.com.
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Product description
Operating Instructions
Chapter 4
4.2.2
The UE410-XM module is the input/output expansion module of the Flexi Classic Muting
system.
The UE410-XM module can be used to implement basic muting functions such as 2 or
4 sensor muting, with or without override. For this purpose it has 2 inputs for connecting
the main sensor that is to be muted, 4 inputs for the muting sensors and 2 control inputs.
Outputs from this module include 2 semiconductor-based, safety-rated outputs, 2 signal
outputs and 2 test outputs.
Mode of operation and parameters are configured using two rotary switches on the upper
surface of the module. The Function A rotary switch is used to define the mode of operation with/without override, muting end condition and direction monitoring. The Function B
rotary switch is used to define muting duration and with/without concurrence monitoring
of sensors.
Functions such as EDM, restart etc. are implemented by control wiring to terminal S1.
Note
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25
Product description
Chapter 4
Operating Instructions
Flexi Classic Muting
4.2.3
Where the application requires it, additional muting functions can be implemented with an
MM or XM module by adding a UE410-MDI module. The user then has a total of three
further control inputs for the integration or evaluation of control or conveyor signals. These
functions are activated and their parameters set using the Function C rotary switch on the
upper face of the module.
Note
UE410-MDI can never be used separately in a Flexi system; it can only be used as an
extension to a muting main module UE410-MM or a muting expansion module UE410-XM.
Connections to muting expansion module UE410-MDI
Inputs
Tab. 10: Inputs of muting
expansion module
UE410AMDI
26
C1
OVR
CS
S4
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Operating Instructions
Product description
Chapter 4
4.3
Flexi Classic Muting modules can be combined with other modules from the Flexi family in
several different ways:
A muting system can, for example, consist of a UE410-MM module with a subsystem
comprising a UE410-XU module and, where necessary, a UE410-8DI module. In this case,
the complete system configuration would be stored in the UE410-MM.
Another example would be a Flexi Classic system comprising a UE410-MU module with a
muting subsystem made up of a UE410-XM module and, where necessary, a UE410-MDI.
Here, the complete system configuration would be stored in the UE410-MU.
Flexi Classic module
main module UE410-MU
input/output expansion module UE410-XU
input expansion module UE410-8DI
Output module UE410-2RO/UE410-4RO
As with the Flexi Classic system, these output modules can also be used to implement
electromechanical contacts for a Flexi Classic Muting module.
Gateways
With a Flexi Classic gateway module, information can be transmitted from a Flexi Classic
Muting module to a non-safety fieldbus.
For further information on the Flexi Classic family and the output modules, see the Flexi
Classic operating instructions (8011737). For further information about gateways, see the
Flexi Classic gateway operating instructions (8011834).
Further information on the Flexi Classic family, the output modules, and gateways, is also
available at www.sens-control.com.
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27
Product description
Chapter 4
Operating Instructions
Flexi Classic Muting
4.4
Module description
Depending on the functional requirements of the muting application, a system will consist
of at least one UE410-MM module or a UE410-XM module. If the functional requirements
cannot be met in this way, an expansion module UE410-XM or UE410-MDI must be used.
The modules and the functions they offer are described below.
Fig. 15: Circuit function
diagram
(1) Not on MM module
(2) Not on XM module
28
Functions
UE410-MM
UE410-XM
Concurrence
Muting duration
Internal override
Direction monitoring
Reset
EDM
UE410-MDI
Sequence monitoring
Supplementary signal C1
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Operating Instructions
Product description
Chapter 4
4.4.1
Number of
muting
Internal
override
Muting end
when ESPE
sensors
possible
clear
Direction
monitoring
Switch setting
2/4
No
No
No
No
No
Yes
2/4
No
Yes
No
No
Yes
Yes
2/4
Yes
No
No
Yes
No
Yes
2/4
Yes
Yes
No
Yes
Yes
Yes
7
8
Not assigned
Number of
Internal
muting sensors override
possible
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Yes
Muting end
when ESPE
Direction
monitoring
Switch setting
clear
No
Yes
29
Product description
Chapter 4
Operating Instructions
Flexi Classic Muting
Concurrence monitoring
Switch setting
20 s
1 min
15 min
60 min
3s
20 s
3s
1 min
3s
15 min
3s
60 min
3s
30
1 min
Concurrence monitoring
3s
Switch setting
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Product description
Operating Instructions
Chapter 4
4.4.2
Module function
The expansion module provides supplementary signal C1, conveyor stop (CS) and an
override input (OVR).
The Function C rotary switch is used for configuration of additional function parameters.
Configuration of UE410-MDI
Tab. 16: Function C rotary
switch on the UE410-MDI
module
Sequence monitoring
C1 evaluation
Switch setting
No
No
No
Yes
Yes
No
Yes
Yes
3
4
5
6
Not assigned
7
8
9
Note
If the conveyor stop (CS) function is not used, the CS input must be connected to +24 V.
Example showing choice of switch setting
(with reference to Table 17)
Required configuration:
sequence monitoring activated
C1 evaluation activated
Result:
switch setting 3
Sequence monitoring
Yes
C1 evaluation
Switch setting
Yes
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31
Configurable functions
Chapter 5
Operating Instructions
Flexi Classic Muting
Configurable functions
5.1
Muting can be achieved using either two or four sensors. The number of sensors used
depends on the geometry of the object to be detected.
The following sensor combinations are possible:
two sensors (one pair of sensors)
two sensors (one pair of sensors) and a supplementary signal C1 (requires module MDI
in addition)
four sensors (two pairs of sensors)
four sensors (two pairs of sensors) and a supplementary signal C1 (requires module
MDI in addition)
The electrical connection of muting sensors is described in the chapter Examples of
applications and connections in the operating instructions of the switching device used.
Note
There must always be connections to all 4 muting sensor inputs, i.e. for applications with
only 2 muting sensors, bridges must be installed between M1 and M3, and M2 and M4.
5.1.1
Supplementary signal C1
You can also connect a supplementary signal C1 to the muting sensors. The signal can be
a control signal from a PLC or from an additional sensor. The supplementary signal C1
must not be a static signal. It will be checked during the muting cycle for dynamic
behavior. If the signal does not change during a cycle, no further muting will take place.
Dynamic sequence of input signals
Fig. 16: Signal sequence with
active input C1 during the
muting cycle
Signal C1
Sensor pair
M1/M2
M1
Sensor pair
M3/M4
M3
M2
M4
ESPE
Muting
Start cycle
32
Transfer
End of cycle
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Operating Instructions
Chapter 5
Note
To activate muting, there must be a LOW/HIGH signal change at input C1 before both
muting sensors of the first pair (e.g. M1 and M2) are active. If this sequence fails,
muting will not occur.
If muting has become active, there must then be a HIGH/LOW signal change at input
C1. If this sequence fails, subsequent muting cycles will not occur.
The supplementary signal C1 is only possible in conjunction with expansion module
MDI.
When sequence monitoring is configured, a LOW/HIGH signal change must occur at
input C1 before the first muting sensor of a pair (M1 or M4) becomes active.
C1 must remain HIGH until a muting sensor is active.
5.2
Time monitoring
5.2.1
Concurrence monitoring
To protect against manipulation (e.g. covering an optical sensor) of the safety application,
concurrence monitoring can be configured.
When this function is selected, both muting sensors must become active within a defined
time (see chapter 13 Technical data on page 58). When this function is not selected,
there is no time monitoring.
Note
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Configuration is carried out using the Function B rotary switch on module UE410-MM or
UE410-XM. The configurable time for concurrence monitoring applies to both sensors of a
pair.
Hazard zone
ESPE
M1
M3
M2
M4
33
Configurable functions
Chapter 5
Operating Instructions
Flexi Classic Muting
5.2.2
When Monitoring the total muting duration is active, the maximum duration of muting is
limited. Monitoring of the total muting duration can be set in stages. The times are
configurable (see chapter 13 Technical data on page 58).
Muting is ended, at the latest, when the total muting duration expires.
Note
When a valid muting state has been achieved for a pair of sensors, it is permissible for one
sensor to briefly change state (become inactive) for a defined time without causing the
muting state to be discontinued (see chapter 13 Technical data on page 58).
Note
To prevent valid muting conditions from being cancelled by the expiry of time monitoring
when the conveyor stops, the function Conveyor stopped and a conveyor-stopped signal
can be used to suspend time monitoring. At the same time, the conditions of the active
muting sensors and the ESPE, when the conveyor has stopped, are monitored for changes.
The following timeout controls are suspended when the conveyor stopped signal is active:
monitoring of the total muting time
concurrence monitoring
When the conveyor restarts, the muting state
continues, if the muting conditions remain valid;
is terminated, if the muting conditions became invalid.
Note
Monitoring of the condition of the sensors and the ESPE begins after a fixed deceleration
time (see chapter 13 Technical data on page 58).
When the Conveyor stopped function is configured, the signal from the conveyor must be
connected to the Conveyor stopped input.
The function Conveyor stopped is only possible in conjunction with expansion module MDI.
Status
HIGH
LOW
If the conveyor stopped (CS) function is not used, the CS input must be connected to
+24 V!
WARNING
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Operating Instructions
Chapter 5
5.2.5
Muting ends when one sensor of the last pair becomes inactive, and, thus, there is no
longer a valid muting condition fulfilled. The function Muting end by ESPE shortens the
duration of muting to the time at which the light beam of the ESPE is cleared again. In this
way, you achieve a shorter muting time and, simultaneously, greater safety.
Fig. 18: Muting end by ESPE
Hazard zone
ESPE
Transport means
Material
M1
M3
M2
M4
M1
M3
M2
M4
Without the function Muting end by ESPE, muting is not ended before one sensor of the
last pair becomes free again .
With the function Muting end by ESPE, muting ends as soon as the ESPE beam is clear
again .
Note
Material and means of transport must be detected by the muting sensors or the ESPE
over their entire length. There must be no detectable gaps, otherwise muting will be
ended too early.
If the ESPE light path does not become clear, then muting will be ended, at the latest,
when the muting condition is no longer met.
Observe the muting-end delay time (see chapter 13 Technical data on page 58).
Configuration of the Muting end by ESPE function is carried out using the Function A
rotary switch on module UE410-MM or UE410-XM.
When muting with 4 muting sensors, detection by the second pair of sensors is
necessary.
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35
Configurable functions
Chapter 5
Operating Instructions
Flexi Classic Muting
5.3
Direction recognition
Conditions to be met
2 (1 pair of sensors)
4 (2 pairs of sensors)
For muting conditions to be met, the object can only move in the defined direction and
sequence through the muting sensors.
Note
Configuration is carried out using the Function A rotary switch on module UE410-MM or
UE410-XM.
5.4
Sequence monitoring
When Sequence monitoring is activated, the sensors must become active and then be
cleared again in a certain sequence. The material must pass completely through the
protective installation for there to be no muting error. In addition, the direction can be
defined by configuring Direction recognition. The following table shows the precise
conditions in relation to the number of sensors.
Tab. 20: Conditions for
sequence monitoring
Conditions to be met
2 (1 pair of sensors)
4 (2 pairs of sensors)
In order to fulfill muting conditions, the object may only move through the muting sensors
in the defined direction and sequence.
Note
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Configurable functions
Operating Instructions
Chapter 5
5.5
Override function
Override is manual initiation of muting after a muting condition error. By briefly simulating
a valid muting condition, you can bypass the protective installation (muting) and run the
system to clear it, or to achieve an error-free state.
The system differentiates between two conditions: Override and Override required.
Override
The Override function is activated using the Function A rotary switch.
Override required
The condition Override required means that the switched outputs (OSSD) are in the OFF
condition and the system is waiting for the Override control to be operated. The system
signals this condition by a blinking muting lamp (2 Hz).
The condition Override required is only triggered by the system when, during a valid muting
condition
an error occurs
and
muting is ended
and
the ESPE is interrupted by an object.
Errors can arise due to concurrence monitoring, total muting time monitoring, direction
recognition, sequence monitoring, and sensor gap monitoring, all governed by the muting
sensors, or due to a restart after an emergency stop or power failure.
Observe the following safety instructions for the Override condition!
WARNING
Install the Override control in a position where the operator has a clear view of the
entire hazardous area.
Before operating Override, ensure that the muting system components are operating
properly, in particular the muting sensors.
When two successive muting cycles require the Override to be used, then the muting
arrangement and muting sensors must be examined and verified for correct operation.
The Override function can only be started in the condition Override required by operating
the Override control. The system will resume muting at the point at which it was interrupted. The switch outputs (OSSD) change to the ON status and the system will then monitor
the Override condition.
Override can be started in two ways:
using a separate Override control (only with the MDI module)
using a common control for Reset and Override
Electrical connection of the control device is described in chapter 9 Examples of
applications and connections from page 47.
Note
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When using a common control device for Reset and Override the Reset and Override input
terminals must be bridged if an MDI module is also used.
37
Configurable functions
Chapter 5
Operating Instructions
Flexi Classic Muting
Permissible number of
Override conditions
Deactivated
Activated
Values:
20 s
60 s
15 m
60 m
Notes
180
60
5
5
Every time the system is switched on, and after a muting cycle in which no errors were
detected the counter for the number of Override cycles allowed is automatically reset.
When the permissible number of muting cycles using Override is exceeded, the system
goes to the Lock-out state. This is indicated by an error signal at the ERR LED.
Concurrence and direction monitoring are deactivated for the duration of Override
operation!
WARNING
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Configurable functions
Operating Instructions
Chapter 5
5.6
Restart interlock
The hazardous movement of the machine is stopped when the optical protective device
is interrupted , and restarting cannot occur until the operator is outside the hazardous
area and operates the Reset button .
Note
Do not confuse the restart interlock with the machine's start interlock. The start interlock
prevents the machine from starting when it is switched on. The restart interlock prevents
the machine from restarting after an error or after a light beam has been interrupted.
You can prevent the machine from restarting in two ways:
with the internal restart interlock in the modules UE410-MM or UE410-XM:
then the muting module controls restarting,
with the restart interlock of the machine (external):
then the muting module has no control over restarting.
The following table shows the possible combinations:
Restart interlock of
muting module
Permissible
applications
Deactivated
Deactivated
Deactivated
Activated
All
Activated
Deactivated
Activated
Activated
When the function is activated, the status Reset required is indicated by the muting lamp
on the Q3 and/or on the Q4 output blinking at a rate of 1 Hz.
Observe the following safety instruction!
WARNING
Always configure an application with restart interlock! Make sure that there is always a
restart interlock. The Flexi Classic Muting family cannot verify if the machine's restart
interlock is connected.
If you deactivate both the internal and the external restart interlocks, you expose the plant
operator to acute danger.
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Configurable functions
Chapter 5
Operating Instructions
Flexi Classic Muting
5.6.1
Reset
When you both activate the restart interlock (internal) and implement the restarting
interlock of the machine (external), then each restart interlock must have its own button.
When the Reset button is operated (for the internal restart interlock), the safety outputs
are activated in the modules UE410-MM and UE410-XM.
Then, only the external restart interlock prevents a restart of the machine. After pressing
the reset button for the muting module, the operator must press the restart button for the
machine. If the reset button and restart button are not operated in the order given, the
dangerous state remains interrupted.
Tab. 23: Reset without MDI
Without MDI
Without EDM
With EDM
Manual reset
Automatic reset
Manual reset
with override
Automatic reset
with override
Recommendation
With the aid of the reset button, you can eliminate unintentional operation of the external
restart button. The user must first acknowledge the safe condition by pressing the reset
button.
5.7
On reset, the static external device monitor checks whether the controlled relays have
dropped out. The external device monitor can thus recognise if, for example, a pair of relay
contacts have become welded. In such cases, the external device monitor switches the
system to a safe condition. Then, the safety outputs are not re-activated.
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Operating Instructions
Chapter 6
Subsystems
Only a UE410-MDIx is allowed to follow immediately after a UE410-MM. Only a UE401MDIxC2 is allowed to follow immediately after a UE410-XM. For further information please
refer to the Flexi Classic configurator at www.sens-control.com.
Exclude cross-circuits by means of appropriate cabling!
WARNING
If several modules are used (UE410-MM and UE410-XM), cross-circuits on safety outputs
(Q1/Q2) can not always be detected.
If several modules are used, the possibility of cross-circuits has to be excluded by
means of appropriate cabling measures (protected installation, control cabinet, plasticsheathed cable etc.).
6.2
Note
Grouping
In case of the single-channel wiring of a safety output (Q1/Q2) to a signal input (EN), if the
wiring is laid with protection, SIL3 in accordance with IEC 61 508, SILCL3 in accordance
with EN 62 061, PL e as per EN ISO 13 849J1 and category 4 as per EN ISO 13 849J1 can
be achieved.
Exclude cross-circuits by means of appropriate cabling!
WARNING
Single-channel wiring is only allowed to be realized with protection (control cabinet, plasticsheathed cable etc.).
If several modules are used, the possibility of cross-circuits has to be excluded by
means of protected installation:
If several modules are used (>1), cross-circuits on control outputs (X1-Xn) can not
always be detected.
If several modules are used (MU and XU), cross-circuits on safety outputs (Q1-Q4)
can not always be detected.
If these conditions cannot be met, then the safety level stated above cannot be achieved.
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41
Chapter 6
Operating Instructions
Flexi Classic Muting
6.3
Note
ENABLE input
For all UE410-MM and UE410-XM devices with a type label entry from E1 the following
applies: In case of the single-channel wiring of a safety output (Q1/Q2) to a signal input
(EN), SIL3 in accordance with IEC 61 508, SILCL3 in accordance with EN 62 061, PL e as
per EN ISO 13 849J1 and category 4 as per EN ISO 13 849J1 can be achieved.
ENABLE function
QStart
(input and output
signal of
start function)
EN
Start interlock
QEN
(output for the
ENABLE function)
WARNING
Single-channel wiring is only allowed to be realized with protection (control cabinet, plasticsheathed cable etc.).
If this condition cannot be met, the safety level stated above cannot be achieved.
The ENABLE input makes it possible to cascade safety circuits or to form subsystems.
ENABLE input has a higher ranking than all other input signals (sensors, muting).
Note
Unused ENABLE inputs must be permanently connected to the supply voltage +UB.
Otherwise the OSSDs (Q1-Q2) can not be released.
When ENABLE input goes to LOW (0 V DC), the OSSDs (Q1-Q4) always go to LOW as well,
and, simultaneously, signals such as Reset and Muting are not recognised until ENABLE
input is HIGH again.
Switching ENABLE off and then on again does not require a new Reset at the appropriate
modules; the OSSDs (Q1-Q4) go to HIGH.
For further information on subsystems and cascading, see operating instructions Flexi
Classic (8011737) or go to www.sens-control.com.
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Operating Instructions
Chapter 7
7.1
The Flexi Classic Muting system must be mounted in an enclosure with at least degree
of protection IP 54.
WARNING
In a Flexi Classic Muting system the main module UE410-MM is installed at the extreme
left, one of the optional gateways, e.g. UE410-PRO, at the extreme right.
Connections between the modules are by means of connectors integrated into the
housings.
The installation must comply with EN 50 274.
The modules are in 22.5 mm wide housings for installation on 35 mm standard DIN
mounting rails to EN 60 715.
Ensure that the grounding clip is correctly seated. The grounding clip of the module
must have secure contact and good electrical conductivity to the DIN mounting rail.
Apply light pressure in the direction of the arrow to click the module on to the DIN
mounting rail .
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Chapter 7
Operating Instructions
Flexi Classic Muting
When several modules are used, slide the modules together in the direction of the
arrows until the connectors between modules are fully engaged.
Install end stops at each end of the module assembly.
7.2
Dismounting modules
Unplug the terminal blocks with their wiring and remove the end stops.
Fig. 24: Separate the
connectors
If there are several modules, slide them apart in the direction of the arrow until the
connectors on the module sides have separated.
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Operating Instructions
Chapter 7
Press the top of the module down at the rear and, while maintaining the pressure,
rotate in the direction of the arrow to remove it from the DIN mounting rail .
7.3
Move the screwdriver upwards to release the cap. The cap can then be removed
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45
Electrical installation
Chapter 8
Operating Instructions
Flexi Classic Muting
Electrical installation
Switch the entire machine/system off line!
WARNING
Notes
The machine/system could inadvertently start up while you are connecting the devices.
The Flexi Classic Muting safety controller fulfils the EMC requirements in accordance
with the basic specification EN 61 000=6=2 for industrial use and EN 61 131=2 for
control systems.
The control cabinet or mounting housing of the Flexi Classic Muting must at least
comply with enclosure rating IP 54.
The modules of the Flexi Classic Muting family conform to Class A, Group 1, in accordance with EN 55 011. Group 1 encompasses all ISM devices in which intentionally
generated and/or used conductor-bound RF energy that is required for the inner
function of the device itself occurs.
Mounting according to EN 50 274
In order to ensure EMC safety, the DIN mounting rail must be connected to FE.
You must connect the Flexi Classic Muting to the same voltage supply as the connected
protective devices.
The voltage supply of the devices must be capable of buffering brief mains voltage
failures of 20 ms as specified in EN 60 204=1.
The voltage supply as well as all signals connected have to fulfil the regulations for
extra-low voltages with safe isolation (SELV, EN 61 140) for overvoltage category III
according to EN 60 664.
For UL 508 and CSA applications a class 2 power supply as per UL 1310 must be used.
If several power supplies are used, the 0 V connections of the power supplies must be
connected to each other.
For installation in environments with overvoltage category III, external protection elements must be used. The required level of protection as per EN 62 305=1 can be
achieved using an external snubber circuit. The protection elements (SPD surge
protective devices) must comply with the requirements as per EN 61 643=11.
The cables of a connected reset button must be laid in separate plastic-sheathed cables.
All connected sensors and downstream controllers and wiring/installation must correspond to the required category according to EN ISO 13 849=1 and to the SILCL according
to EN 62 061 (e.g. protected installation, single plastic-sheathed cable with shielding etc.).
In order to protect the safety outputs and to increase the life of the module, the external
load must be equipped with e.g. varistors and RC circuits. Please also note that the
selection of the arc suppression can increase the total response time of the safety
function.
Single-channel safety outputs, the external device monitoring (EDM) and ENABLE (EN)
must be wired in a protected area (e.g. in the control cabinet). If this condition cannot
be met, the stated safety level cannot be achieved.
External faults (e.g. cross-circuits) between two modules within a Flexi Classic Muting
system are to be avoided through use of appropriate countermeasures (separating
effected wires, shielded cable).
Mount the reset device so that it cannot be actuated by a person located in the
hazardous area. When operating the reset device, the operator must have full visual
command of the hazardous area.
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Operating Instructions
Chapter 9
If all the conditions stated in chapter 3 Muting on page 11 are taken into account and
evaluated in an analysis (e.g. FMEA), applications up to maximum of SIL3 in accordance
with IEC 61 508, SILCL3 in accordance with EN 62 061, PL e as per EN ISO 13 849=1 and
category 4 as per EN ISO 13 849=1 can be realized. In particular the selection of the
muting sensors (see section 3.1.2 Muting sensors on page 12) and their placement (see
section 3.2 Arrangement of muting sensors on page 14) are an important element of the
safety level described.
If the conditions stated there cannot be met, the safety level stated above cannot be
achieved.
Functions:
On selecting the muting sensors please follow section 3.1.2 Muting sensors on page 12.
You will find information on their placement in section 3.2 Arrangement of muting
sensors on page 14.
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Chapter 9
Operating Instructions
Flexi Classic Muting
Functions:
On selecting the muting sensors please follow section 3.1.2 Muting sensors on page 12.
You will find information on their placement in section 3.2 Arrangement of muting
sensors on page 14.
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Operating Instructions
Chapter 9
Functions:
On selecting the muting sensors please follow section 3.1.2 Muting sensors on page 12.
You will find information on their placement in section 3.2 Arrangement of muting
sensors on page 14.
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Chapter 9
Operating Instructions
Flexi Classic Muting
Functions:
On selecting the muting sensors please follow section 3.1.2 Muting sensors on page 12.
You will find information on their placement in section 3.2 Arrangement of muting
sensors on page 14.
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Commissioning
Operating Instructions
Chapter 10
10
Commissioning
No start-up without inspection by a competent person!
WARNING
Before you commission a plant in which you are using a Flexi Classic Muting, the
installation must be examined by a competent person and its release documented.
Before start-up and commissioning, make absolutely certain that there is no one in the
hazard zone.
Check the hazard zone and secure it so that persons cannot enter (e.g. place warning
signs, install a barrier, etc.). Observe applicable laws and local regulations.
10.1
Application acceptance
You may only commission the system if validation was successful. Validation may only be
performed by professionals trained accordingly.
The general acceptance comprises the following test points:
Check whether the connection of the components to the connections corresponds to
the required Performance Level in accordance with EN ISO 13 849=1 or to the SIL in
accordance with IEC 61 508 or the SILCL in accordance with EN 62 061.
Check the devices connected to the safety controller in accordance with the test notes
from the accompanying operating instructions.
Note
You will find the Tests before the first commissioning chapter for this in the operating
instructions of the ESPE from SICK AG.
Clearly mark all connection cables and plugs at the safety controller.
Perform a complete verification of the safety functions of the system in each operating
mode and an error simulation. Observe the response times of the individual
applications in particular.
Completely document the configuration of the system, the individual devices and the result
of the safety check.
Note
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51
Commissioning
Chapter 10
Operating Instructions
Flexi Classic Muting
10.2
Testing instructions
10.2.1
The purpose of the tests before the first commissioning is to confirm the safety requirements specified in the national/international rules and regulations, especially in the
Machinery Directive and the Work Equipment Directive (EU Conformity).
Check the effectiveness of the protective installation mounted on the machine, in all
selectable operating modes and functions.
Make sure that the operating personnel for a machine fitted with a safety controller are
instructed by a competent person before they are allowed to operate the machine.
Instructing the operating personnel is the responsibility of the authority responsible for
the machine.
10.2.2
Periodic testing
WARNING
10.2.3
Check the system according to the valid national regulations within the time limits. The
objective is to discover changes to the machine and manipulations of the protective
installation since first commissioning.
Each safety application must be checked daily or at the start of every shift for correct
operation and detectable manipulations by an authorised and assigned person. In
accordance with the safety performance requirements given in the Technical data, a
complete check of function and wiring must be carried out at appropriate intervals.
If any modifications have been made to the machine or the protective installation, or if
the safety controller has been changed or repaired, then you must check the system
again as specified in the checklist in the Annex.
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Operating Instructions
Commissioning
Chapter 10
10.3
Tab. 24: LED signals
Meaning
Supply voltage OK
M1-M4, I1, I2 on
I1, I2 blink
alternately
M1, M2 blink
alternately
M3, M4 blink
alternately
M1 or M2 blinks
M3 or M4 blinks
EN, S1 on
S1 blinks
Time for operation of the reset button has expired (only for
restart interlock)
Q1, Q2 on
ERR off
Signals of UE410-MDI
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PWR on
Supply voltage OK
ERR off
53
Configuration
Chapter 11
Operating Instructions
Flexi Classic Muting
11
Configuration
Check the configuration for the protective installation after every change!
WARNING
If you change the configuration, you must check that the protective installation is still
effective. When checking the system, observe the testing instructions in the operating
instructions for the protective device used.
For configuring the Flexi Classic Muting modules, you require a screwdriver.
Switch off the power supply to all main modules (terminals A1, A2).
Use the screwdriver to set the rotary switches for the required functions on all system
modules.
Set up the control functions of the system by connecting the external devices at the S1
terminals on the UE410-MM or UE410-XM module.
With the ENTER button on the main module UE410-MU or UE410-MM held down, switch
on the power supply to all main modules.
It is important that no connected RESET button is operated with the system in this
condition!
WARNING
When the display ERR starts to blink, release the ENTER button within 3 seconds.
The configuration is now stored, active, and protected against power loss.
Note
If the ENTER button is pressed for longer than 3 seconds, the whole system goes to the
fault condition. The display ERR blinks (see also section 12.4 Error-LED displays (ERR)
on page 56).
All subsequent changes to the circuits at S1 result in a lockout condition (ERR).
WARNING
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Diagnosis
Operating Instructions
Chapter 12
12
Diagnosis
12.1
Do not run the machine if you cannot clearly determine the cause of a fault!
WARNING
Take the machine out of service if you are not certain of the cause of a fault or are not
sure how to correct it.
12.2
On the occurrence of an error that results in the loss of the safety function, the Flexi Classic Muting modules adopt a defined, safe state.
All safety outputs are shut down (Q1-Q4 = LOW) and the ERR LED flashes.
The Flexi Classic Muting modules remain in this state until the error is rectified and then a
power-up is undertaken.
Errors that can result in the loss of the safety function, can be e.g.:
safety-related internal errors
an invalid start-up configuration
sensor error
supply voltage loss
You will find the complete list in section 12.4 Error-LED displays (ERR) on page 56.
12.3
SICK support
If you cannot remedy an error with the help of the information provided in this chapter,
please contact your local SICK agency.
Note
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When you send a device to us for repair, it will be returned to you with our standard
delivery settings. Please, therefore, note the configuration of your devices before you send
them to us.
55
Diagnosis
Chapter 12
Operating Instructions
Flexi Classic Muting
12.4
This section explains what the ERR-LED displays mean and how you should react to them.
Tab. 25: Fault displays at
ERR-LED
Display
Possible cause
or
or
or
Carry out a power-up and repeat
teach-in
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Operating Instructions
Diagnosis
Chapter 12
12.5
Anti-manipulation measures
Cause
Intentional use of an
incorrect
configuration
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57
Technical data
Chapter 13
Operating Instructions
Flexi Classic Muting
13
Technical data
13.1
Data sheet
13.1.1
Module UE410-MM/UE410-XM
Minimum
Typical
Maximum
19.2 V DC
PELV or SELV
24 V DC
30 V DC
3V
Power consumption
3W
60 s
13 V DC
30 V DC
5 V DC
5 V DC
2.4 mA
3 mA
3.8 mA
2.5 mA
2.1 mA
Input capacitance
9 nF
10 nF
11 nF
70 ms
50 ms
5s
0.9 ms
Muting-on time
70 ms
3s
Number of outputs
Output type
Output voltage
16 V DC
30 V DC
Output current
120 mA
1)
1)
2)
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Operating Instructions
Technical data
Chapter 13
Typical
Maximum
Load capacity
1000 nF
Line resistance
100 ohm
Number of outputs
Type of output
Switching voltage
18.4 V DC
30 V DC
IQn, TA Z 45 C
2.0 A
IQn, TA Z 55 C
1.6 A
\IQn, TA Z 45 C
4A
\IQn, TA Z 55 C
3.2 A
Switching current
TA [C]
TA max
500 ]s
700 ]s
12.5 Hz
32 Hz
370 mJ
Load capacity
500 nF
100 m
13 ms
13 ms
1.5 mm )
3)
3)
4)
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4)
Time without sensor, the data for the sensors connected apply in addition.
Cascading subsystems.
59
Chapter 13
Technical data
Operating Instructions
Flexi Classic Muting
Minimum
Typical
Maximum
3s
Min: 20 s
Max.: 60 min
Off: no monitoring
200 ms
Conveyor stopped
3s
200 ms
0.07 s
0.18 kg
Electrical safety
Class III
Electromagnetic compatibility
Operating data
Operating temperature
25 C
55 C
Storage temperature
25 C
70 C
Relative humidity
10 % to 95 %, non-dewing
Climatic conditions
EN 61 131J2
Operating altitude
Mechanical strength
Vibration
EN 61 131J2
Vibration resistance
1 0.14 mm to 2.5 mm or
2 0.14 mm to 0.75 mm
1 0.25 mm to 2.5 mm or
2 0.25 mm to 0.5 mm (EN 46 288)
8 mm
0.6 Nm
Tightening torque
5-7 lb. in
UE410-xx4XX
Connection cross-section
60
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Operating Instructions
Technical data
Chapter 13
Typical
Maximum
5)
Category
Performance Level
TM (mission time)
PFD
3.9 10
PFHd
2.5 10 h
SFF
96 %
DC
93 %
6
9
The following data apply to the muting expansion module UE410-MDI only. Otherwise, the
general data in section 13.1.1 apply.
Tab. 28: Data sheet
UE410AMDI
Minimum
Typical
Maximum
1.8 W
Number of inputs
13 V DC
30 V DC
5 V DC
5 V DC
2.4 mA
3 mA
3.8 mA
2.5 mA
2.1 mA
70 ms
Input capacitance
9 nF
10 nF
11 nF
0.15 kg
5)
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For detailed information on the safety design of your machine/system, please contact your local SICK
representative.
61
Technical data
Chapter 13
Operating Instructions
Flexi Classic Muting
13.2
Dimensions
13.2.1
93.7
22.5
29
120.8
22.5
78
93.3
96.5
114.4
58
13.2.2
78
58
93.3
96.5
114.4
93.7
120.8
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Operating Instructions
Ordering information
Chapter 14
14
Ordering information
14.1
Available modules
Model
Description
Part Number
UE410-MM3
Main module
6034482
UE410-XM3
Module
6034483
UE410-MDI3
6034484
UE410-MDI3C2
6036291
UE410-MM4
Main module
6034645
UE410-XM4
Module
6034646
UE410-MDI4
6034647
UE410-MDI4C2
6036294
UE410-PRO3
PROFIBUS-DP gateway,
plugs with screw terminals
6028407
UE410-DEV3
DeviceNet gateway
and 4 information signals, 24 VDC,
plugs with screw terminals
6032469
UE410-CAN3
CANopen gateway
and 4 information signals, 24 VDC,
plugs with screw terminals
6033111
UE410-PRO4
PROFIBUS-DP gateway
and 4 information signals, 24 VDC,
plugs with spring terminals
6032678
UE410-DEV4
DeviceNet gateway
and 4 information signals, 24 VDC,
plugs with spring terminals
6032679
UE410-CAN4
CANopen gateway
and 4 information signals, 24 VDC,
plugs with spring terminals
6033112
Other modules
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63
Ordering information
Chapter 14
Operating Instructions
Flexi Classic Muting
14.2
14.2.1
Model
Description
Part Number
RE300-DA03P
6025080
RE300-DA10P
6025079
T4000-2DRNAC
6022052
T4000-1KBA
Actuator
5306531
DOL-1208-G10MA
6022152
IN40-D0101K
6027389
IN40-D0202K
6027392
IN40-D0303K
6027391
DOL-1204-G10M
6010543
Model
Description
Part Number
C4000
All variants
M4000
All variants
C2000
All variants
M2000
All variants
14.2.3
Model
Description
2020743
2019909
2019910
14.2.4
Tab. 33: Part number of
antiAmanipulation cap
64
Part Number
Anti-manipulation cap
Model
Description
Anti-manipulation cap
Part Number
5319789
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Operating Instructions
Annex
Chapter 15
15
Annex
15.1
EC declaration of conformity
EC declaration of conformity
(page 1)
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65
Annex
Chapter 15
Operating Instructions
Flexi Classic Muting
EC declaration of conformity
(page 2)
66
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Operating Instructions
Annex
Chapter 15
15.2
Checklist for the manufacturer/installer for installation of the Flexi Classic Muting modular safety controller
The answers to the questions listed below must be available at least before first commissioning. They depend on the
application, whose requirements the manufacturer/installer has to verify.
This checklist should be retained or included with the machine documentation, so that it can be used as a reference
for the periodic tests and inspections.
1. Were the safety regulations according to the valid directives and standards for the machine used
as a basis?
Yes
No
2. Are the directives and standards used listed in the declaration of conformity?
Yes
No
3. Does the protective device fulfil the required PL/SILCL and PFHd according to
EN ISO 13 849J1/EN 62 061 and the type according to EN 61 496J1?
Yes
No
4. Are the necessary protective measures against electric shock effective (degree of protection)?
Yes
No
5. Has the protective function been checked as specified in the testing instructions in this
documentation? In particular:
Yes
No
Yes
No
function testing of the control elements, sensors and actuators connected to the safety
controller
testing of all switch-off paths
6. Have measures been adopted to ensure that, after every configuration change, a complete check
of the safety functions of the safety controller will be carried out?
This checklist does not replace initial commissioning or regular inspections and tests by a competent person.
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67
Chapter 15
Annex
Operating Instructions
Flexi Classic Muting
15.3
List of tables
Tab. 1:
Tab. 2:
Selection of SICK optical muting sensors with their settings for muting
applications ............................................................................................................. 13
Tab. 3:
Tab. 4:
Tab. 5:
Tab. 6:
Tab. 7:
Tab. 8:
Tab. 9:
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Operating Instructions
Annex
Chapter 15
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15.4
List of figures
Fig. 1:
Fig. 2:
Fig. 3:
Fig. 4:
Fig. 5:
Fig. 6:
Fig. 7:
Fig. 8:
Fig. 9:
Fig. 10:
Fig. 11:
Structure of the Flexi Classic Muting modular safety controller system ..............23
Fig. 12:
Fig. 13:
Fig. 14:
Fig. 15:
Fig. 16:
Signal sequence with active input C1 during the muting cycle ............................32
Fig. 17:
Concurrence monitoring..........................................................................................33
Fig. 18:
Fig. 19:
Fig. 20:
Fig. 21:
Fig. 22:
Fig. 23:
Fig. 24:
Fig. 25:
Fig. 26:
Fig. 27:
Fig. 28:
Fig. 29:
Fig. 30:
Fig. 31:
Fig. 32:
69
Chapter 15
Annex
Operating Instructions
Flexi Classic Muting
70
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Operating Instructions
Annex
Chapter 15
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71
Australia
Phone +61 3 9457 0600
1800 334 802 tollfree
E-Mail sales@sick.com.au
Belgium/Luxembourg
Phone +32 (0)2 466 55 66
E-Mail info@sick.be
Brasil
Phone +55 11 3215-4900
E-Mail sac@sick.com.br
Canada
Phone +1(952) 941-6780
+1 800-325-7425 tollfree
E-Mail info@sickusa.com
Cesk Republika
Phone +420 2 57 91 18 50
E-Mail sick@sick.cz
China
Phone +86 4000 121 000
E-Mail info.china@sick.net.cn
Phone +852-2153 6300
E-Mail ghk@sick.com.hk
Danmark
Phone +45 45 82 64 00
E-Mail sick@sick.dk
Deutschland
Phone +49 211 5301-301
E-Mail kundenservice@sick.de
Espaa
Phone +34 93 480 31 00
E-Mail info@sick.es
France
Phone +33 1 64 62 35 00
E-Mail info@sick.fr
Great Britain
Phone +44 (0)1727 831121
E-Mail info@sick.co.uk
India
Phone +91224033 8333
E-Mail info@sick-india.com
Israel
Phone +972-4-6881000
E-Mail info@sick-sensors.com
Italia
Phone +39 02 27 43 41
E-Mail info@sick.it
Japan
Phone +81 (0)3 3358 1341
E-Mail support@sick.jp
Magyarorszg
Phone +36 1 371 2680
E-Mail office@sick.hu
Nederlands
Phone +31 (0)30 229 25 44
E-Mail info@sick.nl
Norge
Phone +47 67 81 50 00
E-Mail austefjord@sick.no
sterreich
Phone +43 (0)22 36 62 28 8-0
E-Mail office@sick.at
Polska
Phone +48 22 837 40 50
E-Mail info@sick.pl
Romnia
Phone +40 356 171 120
E-Mail office@sick.ro
Russia
Phone +7-495-775-05-30
E-Mail info@sick.ru
Schweiz
Phone +41 41 619 29 39
E-Mail contact@sick.ch
Singapore
Phone +65 6744 3732
E-Mail admin@sicksgp.com.sg
Slovenija
Phone +386 (0)1-47 69 990
E-Mail office@sick.si
South Africa
Phone +27 11 472 3733
E-Mail info@sickautomation.co.za
South Korea
Phone +82 2 786 6321/4
E-Mail info@sickkorea.net
Suomi
Phone +358-9-25 15 800
E-Mail sick@sick.fi
Sverige
Phone +46 10 110 10 00
E-Mail info@sick.se
Taiwan
Phone +886-2-2375-6288
E-Mail sales@sick.com.tw
Trkiye
Phone +90 (216) 528 50 00
E-Mail info@sick.com.tr
United Arab Emirates
Phone +971 (0) 4 8865 878
E-Mail info@sick.ae
USA/Mxico
Phone +1(952) 941-6780
1 800 325-7425 tollfree
E-Mail info@sickusa.com